Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 1 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
LIST OF CONTENTS
PLANT DETAILS
OBJECTIVE
PROPOSAL
SERVICES REQUIRED
SAFETY PRECAUTIONS
EMERGENCY PROCEDURES
STATE OF THE PLANT
METHOD
COMPLETION CRITERIA
APPENDICES
a) DRAWINGS
b) LOG SHEETS.
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 2 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO1.0
2.0
PLANT DETAILS:
The Pre Boiler system consists of Condensate system, Drip system and Feed water system.
The plant under this Pre boiler system mainly consists of following equipments and pressure vessels.
1) Condensate system comprises 3 nos. Condensate Extraction Pumps, Low Pressure Heaters, Gland steam cooler, Drain cooler, Deaerator, connecting pipelines including excess condensate line upto condensate storage Tank.
2) Feed water system comprises 1 No. of H.T. motor driven and 2 Nos Turbo driven Boiler Feed Pumps, their Booster pumps and recirculation lines, High Pressure Heaters, their connecting pipelines upto Economiser inlet. RH & SH spray lines are also included for the purpose of flushing.
3) Drip system comprises the shell side of all LP and HP Heaters and the Drip lines.
4) Temporary circulation pumps (4 nos) each having a capacity of 200 T/hr at 20 Kg/sq cm will be used in this activity. Drawings enclosed in section 10.0 e) provide the layout of connections between temporary and permanent systems.
5) Extraction lines of LP & HP Heaters.
OBJECTIVE:
To remove dirt, oil, grease etc., from the Condensate, Feed water and Drip system, using a non-ionic detergent, prior to putting these systems in regular service. This ensures flow of clean condensate and feed water to the boiler.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 3 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO3.0
3.1
3.2
3.3
3.3.1
3.3.1.1
3.3.1.2
3.3.1.3
PROPOSAL:
Each of the Condensate, Feed water and Drip system shall be flushed separately using fresh detergent.
The three stages are:
Stage – I : Feed lines of Regenerative SystemStage – II : Condensate lines of Regenerative SystemStage – III: Drip lines of Regenerative SystemStage – IV : Detergent flushing of Extraction lines of LP & HP Heaters.
Each system shall be suitably sub-divided into various sub circuits to cover all the lines and components.
STAGE – 1 (Feed Lines Of Regenerative System)This stage is divided into sub- stages 1A, 1B & 1C
Stage – 1 AMixing Tank – Circulating pumps – BFP suction lines (one line at a time) booster pump suction line – feed storage tank – recirculation lines – Mixing Tank.
Stage – 1 BMixing Tank – Circulating pumps – discharge line of BFP by-pass of HP Heaters 5A & 5B and HP Heaters 6A & 6B-feed control station point near economizer inlet valve – Mixing Tank.
Stage – 1CMixing tank – Circulation pumps – S. H. Spray & R.H. Spray lines –feed control station – Point near Economiser inlet valve – Mixing Tank.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 4 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO
3.3.2.0
3.3.2.1
3.3.2.2
3.3.3.0
3.3.3.1
3.3.3.2
3.3.3.3
3.3.3.4
STAGE – II (Condensate lines of Regenerative System)
A Mixing Tank - Circulation pumps – condensate discharge line – by pass Gland steam condenser- by pass of CPU- bypass of drain cooler & LP heater 1 - bypass LPH 2 - bypass LPH 3 - upto a point before deaerator – Mixing Tank. Loop from GSC- Excess condensate Return – Mixing Tank is also to be included.
B Mixing tank – circulation pumps – Condensate discharge line – then through gland steam condenser – bypass of CPU – Drain cooler – Bypass of LPH 1 – LPH 2 – LPH 3 – upto deaerator - Mixing tank.
STAGE: III (Drip lines of Regenerative System)
HP HEATER DRIP LINES:
a) Mixing Tank-circulation Pumps – alternate drip line to HPH 6 A to HP flash tank – HPH 6 A shell – HPH 5 A shell – HPH 5A drip line to Deararator –Mixing Tank.
b) Mixing Tank – circulation Pumps – HPH 6 B alternate drip line to HP flash tank – HPH 6 B shell – HPH 5 B shell – HPH 5 B drip line to Deararator – Mixing Tank.
c) Mixing tank – Circulation pumps – alternate drip line to HPH 5 A HP flash tank – HPH 5 A drip line to deaerator –Mixing Tank.
d) Mixing tank – circulation pumps – alternate drip line of HPH 5 B HP flash tank – HPH 5 B drip line to deaerator –Mixing Tank.
NOTE: In the above, a) , b) and c), d) to be combined.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 5 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO
3.4
LP HEATER DRIP LINES:
e) Mixing Tank – Circulation Pump – alternate drain line from LPH 3 to LP flash tank – LPH 3 shell – Drip line from LPH 3 to LPH 2 – LPH 2 shell –Alternate drain from LPH 2 to LPFT – Mixing Tank.
f) Mixing Tank – Circulation Pump – Alternate drain line from LPH 3 to LPFT – Drip from LPH 3 to LPH 2 -LPH 2 shell – Drip from LPH 2 to LPH 1 – Drip line from LPH 1 to drain Cooler – Drip line from the cooler to LP Flash Tank - Mixing Tank.
In each stage the following activities shall be carried out :-
i. Open circuit Mass flushing in each individual sub circuit with cold water till the effluent is visibly clean.
ii. “Mass flushing in closed circuit with cold water in individual sub circuits is to be done for one hour and sample analysed for turbidity and drained. This process of filling, circulation and draining is to be continued till the turbidity of discharge water is same as that of DM water being used.
iii. Mass flushing in closed circuit with hot water, at a temperature of 600 C, in individual sub circuits is to be done for two hours and sample analysed for turbidity and drained. This process of filling, circulation and drained. This process of filling, circulation and draining is to be continued till the turbidity of discharge water is same as that of DM water being used.
iv. Detergent Flushing for 4 hours each in individual sub circuit.v. Rinsing operation of the entire system as per completion
criteria.vi. Passivation of individual circuit for 8 hours.vii. “Manual removal of debris from FST and other accessible
pipelines.After successful completion of Detergent flushing of Pre-Boiler system, the permanent system is isolated from the temporary system and released for normalisation.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 6 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
SERVICES REQUIRED:
Availability of approximatilly 5000 Tons of DM water for the entire operation.
Availability of nonionic detergent viz Rinopol – Jet 100% OR Sumisol – N 100
Estimated quantity and required concentration is 1000 Litres and 0.05% V/V respectively.
Availability of chemicals for passivation viz.,
i. Hydrazine Hydrate (min. 80% concentration); 800 KG (IS: 12086 / 1991).
ii. (Liquor Amomonia) (Min 25% concentration) 400 KG (IS: 799 / 1985)
Availability of 4 Nos. of temporary circulation pumps having capacity 200 T/Hr and dischage pressure of 20 Kg/sq.cm.
Availability of temporary tank of capacity of 40 cu.metre.
Availability of power supply to temporary circulation pumps.
Availability of adequate lighting in all workings areas.
Availability of reliable communication system such as walkie – talkie sets, telephones etc.
Availability of laboratory facility for analysis of samples of the detergent flushing process.
Availability of workmen with supervisor for round the clock operation with required tools.
STATUS
Signatures NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 7 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO 4.10
5.0
5.1
5.2
5.3
5.4
6.0
6.1
6.2
6.3
Availability of workmen with supervisor for round the clock operation with required tools.
SAFETY PRECAUTIONS:
Readinees of Staircases, platforms, hand rails, approaches etc as decided jointly by BHEL and NTPC at site, should be ensured.
Ensure the availability of First aid facilites during the process.
Ensure the availability Safety and protection equipments like Hand gloves, eye protection equipments, Helmets etc during the process.
Ensure the availability of Service water near the activity area.
EMERGENCY PROCEDURES:
The testing team should be aware of the procedures to be followed in case of accident involving injury to personnel.
The team conducting the flushing activity should be aware of the operating procedures of fire entinguishers to be used for quenching minor fires.
An operator, posted at the pump area, should be instructed to stop the circulation pumps and properly isolate the system in the event of emergency. Emergency operating instructions, in this regards, should be prepared at site.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 8 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SL.NO7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
STATE OF THE PLANT:
Hydraulic test of the entire system to be flushed should be complete.
All the regenerative equipments are installed in position and temporary pipe line connections as shown in the enclosed schemes are completed.
All the isolating valves of the steam extraction lines to heaters are tightly closed. Ensure that all the NRVS in these lines are also closed.
BFP’s, their booster pumps and CEP’s are bypassed suitably with temporary piping.
Suction and discharge ends of BFP’s and CEP’s are capped to prevent the entry of flushing fluid in to the pump.
BFP suction strainer elements are removed before flushing.
All the valves in the steam lines to and from deaerator are closed.
Installation of circulation pumps, mixing tank and connected temporary piping along with pressure gauges is complete.
All H.P. heaters safety valves are removed and blanks are provided with a 1 / 2 “ valve for air venting. Temperature stubs in extraction steam lines for L.P heaters may be used for venting of LP heaters. Care is to taken for venting and proper filling of the heaters. While carrying out the flushing of shell side of HP and LP heaters,
Safety valves of L.P. heaters are erected in position. This is required to release the pressure in the system, incase, the pressure exceeds the set value during the operation due to any unforeseen reasons.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 9 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SL.NO
7.11
7.12
7.13
7.14
7.15
7.16
7.17
7.18
7.19
7.20
All the cutting and welding work on instrument tapping points are complete upto isolating root valves.
No cutting/welding work is permitted to be carried out on any equipment after the flushing is completed.
Deaerator and Hotwell are manually cleaned and inspected jointly.
All the orifices, flow nozzles, control valves and NRVs are removed and spool pieces are to be provided wherever required. A check list we prepared, this would avoid the error during normalization of the system.
All the instruments of the system other then the required ones shall be kept isolated during flushing activity.
All permanent supports are provided for all the pipelines before starting the flushing.
The flushing shall be done as per the schemes attached herewith. Sec. 10.0) e).
The bore of temporary pipe lines should be preferably same as that used in permanent system.
Temporary Mixing tank is provided with 2 Nos of level Indicators.
Temperature gauges with the discharge header of circulation pumps and in the return line to mixing tank provided for monitoring the temperature during the process.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 10 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SL.NO8.08.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
METHOD:Flushing of Regenerative system shall be carried out in three stages as depicted in section 3.0.
Line up the stage to be flushed. Carry out the open circuit flushing of individual sub- stage with cold DM water
Fill the total system with DM water by running Circulation pumps and establish flow of around 100-250 TPH through the circuits/Sub-circuits by operating one pump/Two pumps/Three pumps as per requirement. This is to be suitably decided at site.
Carryout DM water circulation in all the sub loops with cold water as detailed in section 3.3.1, 3.3.2 & 3.3.3 for one hour each to carry out Cold Water Mass Flushing.
Admit steam into the mixing tank and raise the water temperature to 60oC and continue the DM water circulation in all the sub loops as detailed in section 3.3.1, 3.3.2 & 3.3.3 for two hours each to carry out hot Water Mass Flushing. Stop the pumps and drain the system.
Refill the total system with DM water by running circulation pumps and establish circulation.
Admit steam into the mixing tank and raise the water temperature to 60 deg C Add Rinopol – JET 100% OR SUMISOL – N 100 in mixing tank to achieve the solution concentration of 0.05% V/V.
Circulate the solution in each of the loops as per section 3.3.1, 3.3.2 & 3.3.3 for a minimum duration of four hours. During circulation make up shall be made as per the system requirement keeping the solution temperature at 60oC.
On completion of flushing of all the loops, carry out continuous make up and draining in all the loops one by one for duration of 15 minutes each.
STATUS
Signatures NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 11 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO
8.11
8.12
8.13
8.14
8.15
8.16
8.17
Drain the system completely and again fill it with DM water.
DM water shall be circulated in each loop for half an hour once again.
Drain the system completely.
Rinse the system with DM water by continuous filling and draining while keeping the pumps running till effluent is visibly clean and the conductivity and oil parameters meet the values specified in completion criteria.
Stop the pump and drain the whole system.
Fill the system with DM water and establish the circulation. Raise the system temp to 60 deg. C by admitting steam in the mixing tank.
Obtain Hydrazine content of 200 PPM and add Ammonia to get pH value of the solution of the order of 9.5 to 10.0. Raise the temp of the solution to 80 deg. C by steam admission in mixing tank. Maintain the Circulation for 8 Hrs. at this temp. The system is completely drained hot. All air vent valves and feed storage tank manholes are opened to aerate the system.
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 12 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SL.NO
8.18
8.19
8.20
8.21
8.22
9.0
10.0
POST FLUSHING OPERATION:
Remove all the temporary connections from the permanent scheme.
Check that all the pipelines and connections are as per the final scheme.
After draining the deaerator, make internal inspection for foreign material, if any, and clean thoroughly.
After welding of flow nozzle in BFP suction line flush the suction line by draining water from Deaerator for half an hour through each line. For this purpose, temporary pipe connections from suction of each BFP, near the pump, to drain pit is to be made.
After synchronization of the Unit, Drips of LP & HP Heaters are to be taken in the system after checking the quality of drip. (Silica should be less than 20ppb)
COMPLETION CRITERIA:
DM water mixing after chemical flushing shall be considered complete once drained water conductivity is less than 10 micro mhos / cm, and oil content is NIL.
APPENDICES:
STATUS
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 16 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
LOG SHEET # 1PROJECT:
UNIT :
ACTIVITY: DETERGENT FLUSHING OF FEED WATER SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
1. Open circuit flushing of sub stage 1A
Flushing to continue till effluent is visibly clear
2. Open circuit flushing of sub stage 1B
Flushing to continue till effluent is visibly clear
3. Open circuit flushing of sub stage 1C
Flushing to continue till effluent is visibly clear
4. Closed circuit flushing with cold water of sub stage 1 A
1 hr
5. Closed circuit flushing with cold water of sub stage 1 B
1 hr
6. Closed circuit flushing with cold water of sub stage 1 C
1 hr
7. Closed circuit flushing with hot water of sub stage 1 A
2 hr
8. Closed circuit flushing with hot water of sub stage 1 B
2 hr
9. Closed circuit flushing with hot water of sub stage 1 C
2 hr
10. Complete draining of the system.
11. Refilling of the System and establish circulation
12. Raising the water temp. to 60 deg C. and addition of detergent
13. Circulation of detergent solution in sub stages 1A + 1B
4 hr
14 Circulation of detergent solution. In sub stage 1C
4 hr
Signatures
NTPC BHELStation: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 17 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
15. Continuous make up & draining of sub stages 1 A + 1B
15 min
16. Continuous make up & draining of sub stage 1C
15 min
17. Drain the complete system & re-fill with DM water
18. Circulate DM water in sub stage 1A + 1B
1 hr
19. Circulate DM water in sub stage 1C
30 min
20. Drain the system completely21. Rinse sub stage 1A + 1B with
DM water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil.
22. Rinse sub stage 1C with DM water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil.
23. Draining of the system
24. Refill the System and establish circulation
25. Raise the water temp. to 60 deg C and add Hydrazene & Ammonia to required concentration
8 hrs
Hydrazene content should be 200 ppm and add Ammonia to get pH 9.5 to 10
26. Raise the solution temp. to 80 deg C and passivate of the system
8 hrs
27. Drain the system hot
Signatures
NTPC BHELStation: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 18 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
LOG SHEET # 2PROJECT:
UNIT :
ACTIVITY: DETERGENT FLUSHING OF CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
1. Open circuit flushing of sub stage II A
Flushing to continue till effluent is visibly clear
2. Open circuit flushing of sub stage II B
Flushing to continue till effluent is visibly clear
3. Closed circuit flushing with cold water of sub stage II A
1hr
4. Closed circuit flushing with cold water of sub stage II B
1hr
5. Closed circuit flushing with hot water of sub stage II A
2 hrs
6. Closed circuit flushing with hot water of sub stage II B
2 hrs
7. Complete draining of the system.
8. Refill of the System and establish circulation
9. Raise the water temp. to 60 deg C. and addition of detergent
10. Circulation of detergent solution in sub stages II A
4 hrs
11. Circulation of detergent solution. In sub stage II B
4 hrs
12. Continuous make up & draining of sub stages II A
15 min.
13. Continuous make up & draining of sub stage II B
15 min.
14. Drain the complete system & re-fill with DM water
15. Circulate DM water in sub stage 1 hr
IIA Signatures
NTPC BHELStation: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 19 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
16. Circulate DM water in sub stage II b
1 hr
17. Drain the system completely18. Rinse sub stage II A with DM
water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil .
19. Rinse sub stage II B with DM water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil.
20. Draining of the system
21. Refilling of the System and establish circulation
22. Raise the water temp. to 60 deg C and add Hydrazene & Ammonia to required concentration
8 hrs
23. Raise the solution temp. to 80 deg C and passivate sub stage II A
8 hrs
24 Raise the solution temp. to 80 deg C and passivate sub stage II B
25. Drain the system hot
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 20 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
LOG SHEET #3
PROJECT :UNIT :ACTIVITY : DETERGENT FLUSHING OF HP HEATERS DRIP SYSTEM
SN ActivityDura
tion
StartTime / date
Finish time / date
Remarks
1. Open circuit flushing of sub stage III A
Flushing to continue till effluent is visibly clear
2. Open circuit flushing of sub stage IIIB
Flushing to continue till effluent is visibly clear
3. Open circuit flushing of sub stage IIIC
Flushing to continue till effluent is visibly clear
4. Open circuit flushing of sub stage IIID
Flushing to continue till effluent is visibly clear
5. Closed circuit flushing with cold water of sub stage IIIA
1hr.
6. Closed circuit flushing with cold water of sub stage IIIB
1hr.
7. Closed circuit flushing with cold water of sub stage IIIC
1hr.
8. Closed circuit flushing with cold water of sub stage IIID
1hr.
9. Closed circuit flushing with hot water of sub stage IIIA
2hr.
10 Closed circuit flushing with hot water of sub stage IIIB
2hr.
11. Closed circuit flushing with hot water of sub stage IIIC
2hr.
12. Closed circuit flushing with hotwater of sub stage IIID
2hr.
13. Complete draining of the system
14. Refilling of the System and establish circulation
15. Raising the water temp. to 60 deg C. and addition of detergent
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 21 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
16. Circulation of detergent solution in sub stages IIIA
4hr.
17. Circulation of detergent solution in sub stages IIIB
4hr.
18. Circulation of detergent solution in sub stages IIIC
4hr.
19. Circulation of detergent solution in sub stages IIID
4hr.
20. Continuous make up & draining of sub stages IIIA
15min
21. Continuous make up & draining of sub stages IIIB
15min
22. Continuous make up & draining of sub stages IIIC
15min
23. Continuous make up & draining of sub stages IIID
15min
24 Drain the complete system & refill with DM water
25. Circulate DM water in sub stage IIIA
1hr.
26. Circulate DM water in sub stage IIIB
1hr.
27. Circulate DM water in sub stage IIIC
1hr.
28. Circulate DM water in sub stage IIID
1hr.
29. Drain the system completely30. Rinse sub stage IIIA with DM
water by continuous filling & draining.
Rinising is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
31. Rinse sub stage IIIB with DM Rinising is considered
water by continuous filling & draining.
complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 22 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
32. Rinse sub stage IIIC with DM water by continuous filling & draining.
Rinse sub stage IIIDwith DM water by continuous filling & draining.
Rinising is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
Rinising is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
33. Drain the system
34. Refill the system and establish circulation
35. Raise the water temp. to 60 deg C and add Hydrazene & Ammonia
Hydrazene content should be 200 ppm and add Ammonia to get pH 9.5 to 10
36. Raise the solution temp. to 80 deg C and passivate sub stage IIIA
8 hrs.
37. Raise the solution temp. to 80 deg C and passivate sub stage IIIB
8 hrs.
38. Raise the solution temp. to 80 deg C and passivate sub stage IIIC
8 hrs.
39. Raise the solution temp. to 80 deg C and passivate sub stage IIID
8 hrs.
40. Drain the system
Signatures
NTPC BHEL
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 23 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
LOG SHEET #4
PROJECT :
UNIT :
ACTIVITY : DETERGENT FLUSHING OF LP HEATERS DRIP SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
1. Open circuit flushing of sub stage IIIE
Flushing to continue till effluent is visibly clear
2. Open circuit flushing of sub stage IIIF
Flushing to continue till effluent is visibly clear
3. Closed circuit flushing with cold water of sub stage IIIE
1hr.
4. Closed circuit flushing with cold water of sub stage IIIF
1hr.
5. Closed circuit flushing with hot water of sub stage IIIE
2hrs.
6. Closed circuit flushing with hot water of sub stage IIIF
2hrs.
7. Complete draining of the system
8. Refill the System and establish circulation
9. Raise the water temp. to 60 degC. And add detergent
10. Circulate the detergent solution in sub stage IIIE
4hrs.
11. Circulate the detergent solution 4hrs
in sub stage IIIF .12. Continuous make up & draining
of sub stage IIIE15min
13. Continuous make up & draining of sub stage IIIF
15min
14. Drain the complete system &refill with DM water
Station: NTPC- Ramagundam
BHEL Ref No.PS-DC-202-500-0001NTPC Ref no RGM /1/TS/2/002 Sheet 24 of 25
Plant area: TURBINEDETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SN ActivityDura
tion
Start time/dat
e
Finish time/dat
eRemarks
15. Circulate DM water in sub stage IIIE
1hr.
16. Circulate DM water in sub stage IIIE
1hr.
17. Drain the system completely
18. Rinsing of sub stage IIIE with DM water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
19. Rinsing of sub stage IIIFwith DM water by continuous filling & draining
Rinsing is considered complete, when water conductivity is less than 10 micro mhos / cm and oil content is nil
20. Drain the system21. Refill the System and establish
circulation22. Raise the water temp. to 80 deg
C and add Hydrazene & Ammonia
Hydrazene content should be 200 ppm and add Ammonia to get pH 9.5 to 10
23. Raise the solution temp. to 80 deg C and passivate of the sub stage IIIE
8hrs
24. Raise the solution temp. to 80 deg C and passivate of the sub stage IIIF
8 hrs
25. Drain the system hot
Signatures
NTPC BHELSHEET 25 OF25
DETAILS OF CHEMICALS USED DURING THE PROCESS
SN
SYSTEM ACTIVITY NAME OF CHEMICALS ADDED
QUANTITY
FEED WATER
CONDENSATE
DRIP (HP HEATERS)
DRIP (LP HEATERS)
REMARKS :
Signatures
NTPC BHEL
DETERGENT FLUSHING OF PREBOILERAND CONDENSATE SYSTEM
PS:TSX:159:00:03
PROJECT : RAMAGUNDAM 500 MW
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED(A Government of India Undertaking)
Power Sector – Southern Region474, Anna Salai, Nandanam, Chennai – 600 035.
PROJECT RAMAGUNDAM 500MW
PROCEDURE DETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
PURPOSE OF DOCUMENT FOR EXECUTION / INFORMATION
DOCUMENT NO. PS:TSX:159:01:03
COPY NO:
ISSUED TO:
00 K.J K.R K.B 18-08-03
Rev. No. Prepared by Reviewed by Approved by Date
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED(A Government of India Undertaking)
Power Sector – Southern Region474, Anna Salai, Nandanam, Chennai – 600 035.
DETERGENT FLUSING OF PRE-BOILER & CONDENSATE SYSRAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX :
00134:01DRAWN CHECKED APPROVED DATE
KJ K.R K.B 18-08-03
DETERGENT FLUSING OF PRE-BOILER & CONDENSATE SYSRAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX :
00135 :01DRAWN CHECKED APPROVED DATE
KJ K.R K.B 18-08-03
DETERGENT FLUSING OF PRE-BOILER & CONDENSATE SYSRAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX :
00136 :01DRAWN CHECKED APPROVED DATE
KJ K.R K.B 18-08-03
DETERGENT FLUSHING OF PRE-BOILER AND CONDENSATE SYSTEM, RAMAGUNDAM 500MWFEED WATER LINES
DETERGENT FLUSHING OF PRE-BOILER AND CONDENSATE SYSTEM, RAMAGUNDAM 500MWCONDENSATE SYSTEM
DETERGENT FLUSHING OF PRE-BOILER AND CONDENSATE SYSTEM, RAMAGUNDAM 500MWHEATERS AND DRIP SYSTEM
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